A610G Aerospace Applications

AEROSPACE

A610G

APPLICATIONS

2

INDEXAEROSPACE

AIR FRAMEy CFRP y CF/AI y CF/Ti

y Titanium Alloy

Drilling

Face Milling, Pocket Milling

Side Milling, Pocket Milling

High effi ciency machining of laminated board (CFRP, CFRP/Al) is achieved by using the MCS drill and S-TAW drills with CVD diamond coating. Burrs and delamination are decreased.

High effi ciency is achieved by using the AXD series.Metal removal of up to 10000cm3/min. is achieved.

Stable machining is achieved by using the Coolstar series. Adhesion resistance and chip removal are excellent.

Drilling


High effi ciency machining of laminated board (CFRP, CFRP/Ti) is achieved by using PCD drills (sintered diamond).Burrs and delamination are decreased.

High effi ciency machining is achieved by using ALIMASTER end mills.Metal removal up to 5000cm3/min. is achieved.

TrimmingHigh-quality machining is achieved by using DFC end mills with CVD diamond coating. Burrs and delamination are decreased.

y Aluminium Alloy

MCS Drill S-TAW Drill

PCD Drill

DFC End mill

AXD Series

ALIMASTER

Coolstar Series

3

Copy TurningExtended tool life achieved by using GY series with a sharp geometry breaker for low feed rates.

External and Internal TurningTool-life extended 1.5 times by using US905 grade on Ni-based alloy.

DrillingExtended tool life by using MMS with TRI-Cooling technology.

Helical Cutting, Profi le MillingHigh effi ciency machining is achieved by using an ARX type cutter.

External and Internal TurningThe fi rst recommendation is a non-coated grade when fi nish machining titanium alloys.

External and Internal TurningSuccess achieved by using VP05RT when rough machining maraging steel.

Rough MillingStable high effi ciency machining with the VFX cutter. VFX provides high rigidity and low cutting resistance.

Finish Profi le MillingVibration is prevented by using the vibration control end mills, additionally an excellent workpiece surface fi nish is achieved.

Rough Pocket MillingLong tool life machining is achieved by using APX series that features a synergy effect of insert grade and the low cutting-resistance edge.

ENGINE

LANDING GEAR

y Ni-based Superalloy

y Titanium Alloy

y Maraging Steel

y Titanium Alloy

GY Series

FJ/MS/GJUS905/VP05RT/VP10RT

MMS Drill

ARX

FJ/MS/GJRT9010

FJ/MS/GJVP05RT/VP10RT

VFX6

Vibration ControlEnd Mill Series

APX Series

4

Key Point on Machininga Tool life is extremely short because carbon fibre has high strength and when

drilling composite materials, burrs and delamination are easily generated.It is effective to use a tool that has a high wear resistance coating. The MCS drill and S-TAW drills (special order) decrease burrs and delamination due to the CVD diamond coating and their optimized geometry. Long tool life and high-quality drilling became possible.

Drill ø 6.375Cutting Speed vc100 m/min (4995 min-1)Feed f0.04 mm/revMachine Vertical type M/CCoolant Internal air blow

Work Material MCS Conventional Afor CFRP

Conventional Bfor CFRP + Al

CFRP Bottom side of CFRP

CFRP + AlBottom side of aluminium alloy

CFRP

CFRP

Aluminium alloy (A7075)

5mm

5mm

13mm

DrillingMCS Drill

(TOOLS NEWS B184G)S-TAW Drill

(Special insert)

AIR FRAMEWork Materials [CFRP, CF/Al]

Application Examplea CVD diamond coated drills with optimized cutting

geometry for composite materials reduce burr formation and delamination.

Burrs

Burrs

New CVD diamond coated drills

Optimized cutting geometry

5

Drill ø 6.375Work Material CFRP + Titanium alloy (Ti-6Al-4V)Cutting Speed vc10 m/min (500 min-1)Feed f0.05 mm/revMachine Vertical type M/CCoolant Internal mist

CFRP

Titanium alloy5mm

10mm

Good edge condition (120 hole machined)

DrillingPCD Drill

(Special)

PCD drills


AIR FRAMEWork Materials [CFRP, CF/Ti]


drilling composite materials, burrs and delamination are easily generated.It is effective to use a tool that has PCD (sintered diamond) with high wear resistance. A PCD drill (special order) with optimized geometry and PCD coating (sintered diamond) decreases burrs and delamination. Long tool life and high-quality drilling became possible.

Application Examplea PCD drills with optimized cutting geometry for

composite materials reduces burr formation and delamination.

6

End mill DFC4JCD1000 (ø 10)Work Material CFRPRevolution n6000 min-1 (vc188 m/min)Feed vf750 mm/min (fz0.03 mm/tooth)Depth of Cut ap5 mmCoolant Air blow

DFC4JCD1000 Conventional

Cutting direction Cutting direction

No burr formation

Many burr formation

Trimming

DFC End mill(TOOLS NEWS B189G)

New CVD diamond coated end mills


AIR FRAMEWork Materials [CFRP]


drilling composite materials, burrs and delamination are easily generated.It is effective to use a tool that has high wear resistance coating. DFC end mills decrease the burrs and the delamination due their CVD diamond coating and optimized cutting geometry. Long tool life, high-quality milling became possible.

Application Examplea CVD diamond coated end mills with optimized

cutting geometry for composite materials reduce burr formation and delamination.

7

Holder AXD7000R05003A-H63AInsert (Grade) XDGX227030PDFR-GL (TF15)Work Material A7075Cutting Speed vc2830 m/min (n18000 min-1)Feed fz0.21 mm/tooth (vf11340 mm/min)Depth of Cut ap18 mm, ae50 mmCoolant Emulsion

*Overseas major aerospace manufacturers using 50 pieces or more.

ae50mm

ap18mm

AXD Series(TOOLS NEWS B116G)


Low cutting resistance

Convex cutting edge

Helical fl ank

AIR FRAMEWork Materials [Aluminium Alloy]

Key Point on Machininga When milling rib type components where stock material removal is over 90%,

high speed and high efficiency machining is necessary to reduce costs. The AXD series achieves low cutting resistance without lowering the insert edge strength due to a helical flank and optimized of the relief angle.Additionally, the convex cutting edge allowed good chip removal, resulting in high speed, high efficiency machining.

Application Examplea Chip removal 10000cm3/min. is achieved by the

super-high efficiency machining of the AXD7000-HSK type.

Avoids poor wall surface finishes because the tool is designed to Interpolate corners of the pocket, thereby also preventing vibration.

Point

8

End mill CSRARBD2500R300 (ø 25/R3)Work Material A7075Cutting Speed vc1178 m/min (n15000 min-1)Feed fz0.22 mm/tooth (vf10000 mm/min)Depth of Cut ap25 mm, ae20 mmCoolant Emulsion

Avoids poor wall surface finishes because the tool is designed to Interpolate corners of the pocket, thereby also preventing vibration.

15000min-1/75kW, BT50

ae20mm

ap25mm

ALIMASTER(TOOLS NEWS B118G)

Face Milling, Pocket Milling Improved chip removal

Chip fl ow Chip fl ow

Instability in chip separation

Smooth chip separation

AIR FRAMEWork Materials [Aluminium Alloy]

Key Point on Machininga When milling rib type components where stock material removal is over 90%,

high speed and high efficiency machining is necessary to reduce costs.The ALIMASTER series achieves good chip removal due to the unique cross-sectional shape of the flute geometry shape. This enabled high speed, high efficiency machining.

Application Examplea Chip removal 5000cm3/min. is achieved when using

the high power main machine axis at high-speeds.

<Machine specifi cation>

Competitor Mitsubishi

Point

9

End mill VF6MHVCHD1600 (ø 16)Work Material Ti-6Al-4VCutting Speed vc150 m/min (n3000 min-1)Feed fz0.1 mm/tooth (vf1800 mm/min)Depth of Cut ap24 mm, ae1.6 mm (Trochoid)Coolant Emulsion (0.7 MPa)

Titanium alloy

21mm

1.6m

m24

mmConventional

(External coolant)

Feed rate:1800mm/min (0.1mm/tooth)

Feed rate:1350mm/min (0.075mm/tooth)

Side Milling, Pocket Milling

Coolstar Series(TOOLS NEWS B171G)

VF-6MHV-CH

Excellent cooling effect

Multiple internal coolant holes

Unique fl ute geometry

AIR FRAMEWork Materials [Titanium Alloy]

Key Point on Machininga When milling titanium alloys adhesion is easily generated, thermal

conductivity is low and heat concentrates on the cutting edge, it is important to remove heat at the cutting edge efficiently and also to evacuate chips smoothly. The Coolstar series achieves optimum cooling effect and chip removal due to the multi coolant holes and unique flute shape. Stable machining became possible for difficult-to-cut material applications.

Application Examplea No adhesion due excellent cooling effect of the

multi coolant holes.

Excellent chip

removal andcooling.

Adhesion

10

Holder GYHL2525M00-M25LInsert (Grade) GY2M0600J040N-GS (VP10RT)Work Material WaspaloyCutting Speed vc35 m/minFeed f0.05 mm/revDepth of Cut ap10 mmCoolant Emulsion

Further use is possible because of small wear. (after 25 min. machining)

MIRACLE® coating

Carbide substrate(HRA92.0)

VB: 0.122mm VP10RT

Copy Turning GY Series(TOOLS NEWS B140G)

Good cutting performance

GS Breaker(Low feeds)

ENGINEWork Materials [Ni-based Superalloy]

Key Point on Machininga Ni-based alloy machining requires a sharp edge geometry.

An increase in tool life can be achieved by using GS breaker that is designed to decrease the cutting resistance.

Application Examplea Stable machining is possible on super heat-

resistant alloys.

11

Holder DCLNL3225P32Insert (Grade) CNMG120408-MS (US905)Work Material Inconel® 718Cutting Speed vc80 m/minFeed f0.15 mm/revDepth of Cut ap0.25 mmCoolant Emulsion

1.5 times

External and Internal Turning HSK-T Tools

(TOOLS NEWS B134G)FJ/MS/GJ

US905/VP05RT/VP10RT(TOOLS NEWS B036G)



Key Point on Machininga US905 grade for finish-machining of Ni-based alloys. Can be used at higher-

speeds when machining Ni-based alloys than VP05RT and VP10RT with PVD coating that are usually used at 50m/min. machining speeds or less.

Application Examplea Possible to use for high speed finish machining of

super heat resistant alloys.

US905

Conventional

100 20 30

MS Breaker

Tool life (min)

12

Drill (Grade) MMS0610X3D (DP7020)Work Material Inconel® 718Cutting Speed vc14 m/minFeed f0.06 mm/revHole Depth 15 mmCoolant Emulsion

VB: 0.21mm

DrillingMMS Drill

(TOOLS NEWS B180G)


Key Point on Machininga When drilling Ni-based alloys, a major factor is how to cool the cutting edge.

It is possible to extend tool life greatly by using a solid carbide drill that uses TRI-Cooling through coolant technology together with a high-pressure coolant supply.

Application Examplea 15 times tool life is achieved when using high-

pressure internal coolant and TRI-cooling technology.

MMS: Internal coolant (7 MPa)

MWS: Internal coolant (1.5 MPa)

MWE: External coolant

15

1

1

50 10 15

“TRI-Cooling Technology”

Excellent cooling effect

15 times

Tool life (hole)

13

øDHødc

øD1

Holder ARX35R142SA12SInsert (Grade) RDMW0724M0E (VP15TF)Work Material Inconel® 718Cutting Speed vc30 m/minFeed f0.2 mm/rev (Helical Cutting)Hole Depth 20 mm (1 mm/rev), Hole dia. 25 mmCoolant Emulsion

y Helical Cuttinga Setting a tool's centre excursion

Tool's center excursion

Required bore diameter

Tool's cutting diameter

ødc = øDH - øD1

VB: 0.08mm

Helical Cutting, Profile Milling ARX

(TOOLS NEWS B066G)


Key Point on Machininga For machining of holes on the outer side of the engine cases, helical

machining with a small diameter radius insert end mill is effective. Additionally it delivers an excellent machining performance when profile machining on the outer faces.

Application Examplea Large hole machining of super heat-resistant alloys

is achieved by helical machining with a small diameter, indexable insert, radius end mill.

Multifunction

Further use is possible because of small wear. (after 7 min. machining)

14

Holder H63T-DCLNR-DX12Insert (Grade) CNGG120408-FJ (RT9010)Work Material Ti-6Al-4VCutting Speed vc80, 120 m/minFeed f0.15mm/revDepth of Cut ap0.25 mmCoolant Emulsion

Over 3 times

External and Internal Turning

HSK-T Tools(TOOLS NEWS B134G)

FJ/MS/GJRT9010

(TOOLS NEWS B036G)


ENGINEWork Materials [Titanium Alloy]

Key Point on Machininga Rough estimate of the tool life is 120 minutes at 80m/min, 60 minutes at 120m/

min, when finish-machining titanium-alloy. Non-coated grades are the first recommendation.

Application Examplea Over 3 times tool life is achieved by setting

appropriate cutting conditions.

Cutting Speedvc80 m/min

Cutting Speedvc120 m/min

300 60 90 120 150 180 210

FJ Breaker

Tool life (min)

15

Holder PSC63-DDJNRInsert (Grade) DNMG150412-MS (VP05RT)Work Material Maraging Steel (48-50HRC)Cutting Speed vc90 m/minFeed f0.23 mm/revDepth of Cut ap2 mmCoolant Emulsion

2 times

External and Internal Turning

FJ/MS/GJVP05RT/VP10RT(TOOLS NEWS B036G)

HSK-T Tools(TOOLS NEWS B134G)


ENGINEWork Materials [Maraging Steel]

Key Point on Machininga When rough machining engine shafts made from maraging steel, the use of

grades for hard materials such as VP05RT through to the use of the CBN is recommended.

Application Examplea 2 times tool life is achieved by using VP05RT.

VP05RT

Conventional

50 10

MS Breaker

Tool life (min)

16

Holder VFX6-080A05A075RInsert (Grade) XNMU190912R-MS (MP9030)Work Material Ti-5Al-5Mo-5V-3CrCutting Speed vc40 m/min (n160 min-1)Feed fz0.1 mm/tooth (vf80 mm/min)Depth of Cut ap65 mm, ae5 mmCoolant Emulsion (8 MPa)

Rough Milling

VFX6(TOOLS NEWS B182G)

Cutting force

LANDING GEARWork Materials [Titanium Alloy]

Key Point on Machininga When rough machining titanium alloy, chipping and abnormal damage of the

cutting edge easily occurs if low rigidity tools are used. Using high rigidity tools and low cutting resistance inserts is recommended. Stable machining is possible because the VFX series is a high rigidity design and cutting resistance is lower due to the convex curve cutting edge and the V-formation of the clamping face.

Application Examplea Over 7 times tool life is achieved in combination

with high-pressure internal coolant.

VFX

Conventional

300 60 90 120 150 180 210

Over 7 times

Arranging the inserts vertically

Convex curvecutting edge

V formation of the clamping face

Tool life (min)

%°

%°

$°

$°

17

End mill VF4SVBR1000Work Material Ti-10V-2Fe-3AlCutting Speed vc200 m/min (n3400 min-1)Feed vf1020 mm/minDepth of Cut ap1.0 mm, ae0.5 mmCoolant Emulsion

Finish Profile Milling

Vibration ControlEnd Mill Series(TOOLS NEWS B178G)

Wider chip pocket

Variable curve

Variable pitch


Key Point on Machininga When profile machining titanium alloy, chipping and abnormal damage of the

cutting edge can occur and vibration is easily generated.Use of a tool which is designed for vibration control is effective.The latest vibration control series end mills have variable pitch geometry with newly designed radius-cutting-edges that reduce vibration.

Application Examplea 3 times tool life and stable machining is achieved

when no vibration occurs.

VF4SVB

VF6SVB (Special)

300 60 90

3 times

Special: increased number of teeth

Variable pitch

Newly designed radius cutting edges

reduce vibration

Tool life (min)

%°

%° $°

$°

18

%%%%%%%°°°°° $$$$$$$$$°°°°°

End mill VF6MHVR1600 (ø 16)Work Material Ti-6Al-4VCutting Speed vc150 m/min (n3000 min-1)Feed fz0.075 mm/tooth (vf1350 mm/min)Depth of Cut ap16 mm, ae0.8 mmCoolant Emulsion

No vibration

Chatter mark

ae 0.8mm

ap 16mm

Finish Pocket Milling

Vibration ControlEnd Mill Series(TOOLS NEWS B133G)

Improved chip disposalNew fl ute geometry suitable for irregular helix angles.


Key Point on Machininga When finish machining titanium alloy, chipping and abnormal damage of the

cutting edge can occur and vibration is easily generated.Use of a tool which is designed for vibration control is effective.

a The latest vibration control series end mills promote stable machining with variable pitch geometry and irregular helix flutes for improved chip disposal and reduced vibration.

Application Examplea 7 times tool life and stable machining is achieved

when no vibration occurs.

VF6MHV

Conventional

300 60 90

7 times

Irregular helix fl utes

Special fl ute geometry

Tool life (min)

19

Holder (Screw-in type) APX3000R254M12A35 SC25M12S125SWInsert (Grade) AOMT123620PEER-M (VP20RT)Work Material Ti-6Al-4VCutting Speed vc40 m/min (n510 min-1)Feed fz0.08 mm/tooth (vf160 mm/min)Depth of Cut ap6 mm, ae25 mmCoolant Emulsion

Screw-in head

Carbide shank

Edge condition (85min.)

Rough Pocket Milling

APX Series(TOOLS NEWS B055G)

Depth 80mm

Double-phased helical rake angles

Tough cutting edge (Convex curve)


Key Point on Machininga When rough machining titanium alloy, chipping and abnormal damage of the

cutting edge can and vibration is easily generated.a The APX series offers stability with low cutting resistance inserts that have

unique a convex curve shaped cutting edged and a high rigidity cutter body with internal coolant holes.

Application Examplea Long tool life is achieved even on long reach

applications by combining a screw-in head and carbide shank.

High rigidity cutter bodies

Low cutting resistance insert

TIANJIN TIANLING CARBIDE TOOLS CO. LTD.TIANJIN LINGYUN TOOL DESIGN CO. LTD.(China)

MMC TAISHIN TOOL CO., LTD.(Taiwan)

MMC TOOLS (THAILAND) CO., LTD.(Thailand)

MITSUBISHI MATERIALSESPAN~A, S.A.(Espana)

MMC HARTMETALL GmbH (Germany)

MMC HARDMETAL POLAND SP.z o.o. (Poland)

MMC HARDMETAL OOO LTD. (Russia)

MMC METAL FRANCE S.A.R.L. (France)

MMC ITALIA S.R.L(Italy)

MMC Hardmetal (Thailand) Co., Ltd.(Thailand)

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AgencyRepresentative OfficeFactorySales Office

JAPANMITSUBISHI MATERIALS CORPORATIONArea Marketing & Operations DepartmentKFC bldg., 8F, 1-6-1, Yokoami, Sumida-ku, Tokyo 130-0015 JAPANTEL +81-3-5819-8771 FAX +81-3-5819-8774

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EXP-11-E0142011.9.E(1B)

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Global Network

A610G Aerospace Applications

Business

long tool life machining

optimized cutting geometry

optimized geometry

extended tool life

internal turning toollife

composite materials

pcd sintered diamond

low cutting resistance